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PERFORMANCE SPECIFICATION FOR AUTOMOTIVE ELECTRICAL CONNECTOR SYSTEMS The research data, analysis, conclusion, opinions and other contents of this document are solely the product of the authors. Neither the Society of Automotive Engineers, Inc. (SAE) nor the United States Council for Automotive Research (USCAR) certifies the compliance of any products with the requirements of nor makes any representations as to the accuracy of the contents of this document nor to its applicability for purpose. It is the sole responsibility of the user of this document to determine whether or not it is applicable for their purposes. Copyright 2004, USCAR All rights reserved. Printed in U.S.A. Issued August 1997 Revised May 2004 SAE/USCAR-2 Revision 4 QUESTIONS REGARDING THIS DOCUMENT: (724) 772-8518 FAX (724) 776-3036 TO PLACE A DOCUMENT ORDER: (724) 776-4970 FAX (724) 776-0790 TABLE OF CONTENTS 1. SCOPE .4 2. OUTLINE one with the associated Wedge (TPA, PLK, etc.) installed and a second value without such assistance. Room Temperature: 23C + 5C. Separating Force: The force required to disengage a mated pair of contacts (terminals) or a contact and a mating test gage. Signal Circuit: Any electrical circuit expected to carry 5A or less at all times. Soak: Refers to a time period during which the device under test is exposed to stated environmental conditions, such as temperature, humidity, current flow, etc. This exposure may be for the purpose of conditioning the sample prior to another test, or may itself form part of a given test. Special Tool: A tool specifically designed to mate and/or unmate a connector, or to insert and/or remove a connector terminal or other component. Sprung : (Adj.) Describes any portion or component of a motor vehicle that is supported by the suspension system. Sprung components do not include tires, wheels, hubs, or outboard disc. or drum brake assemblies. SAE/USCAR-2 Revision 4 Revised May 2004 PERFORMANCE SPECIFICATION FOR AUTOMOTIVE ELECTRICAL CONNECTOR SYSTEMS - 83 - Shorting Bar: A mechanical device within a connector designed to electrically short two or more circuits together when the connectors are not mated. Shorting Bars may act to overcome the effects of static electricity or to act as a means of detecting when connectors are disconnected. Steady State: A condition of environment or current flow that remains stable for 1 minute or more. Total Connection Resistance: Electrical resistance of one terminal to terminal interface plus the resistance of the conductor to terminal grip for each terminal. For Header type connections, only the resistance of the one conductor to terminal grip is included. Included is the bulk resistance of the terminal material itself. Unmating Force: The force required to unmate male and Female Connector halves or a connector from a device Header or receptacle. Un-sprung: (Adj) Describes any component of a motor vehicle that is not supported by the suspension system. (see Sprung) SAE/USCAR-2 Revision 4 Revised May 2004 PERFORMANCE SPECIFICATION FOR AUTOMOTIVE ELECTRICAL CONNECTOR SYSTEMS - 84 - APPENDIX B: GLOSSARY OF TERMS AIAG Automotive Industry Action Group. Contact at AIAG, Box 77000, Detroit, Michigan 48277-0839. Phone (248) 358-3570. website CPA Connector Position Assurance. Essentially a lock on the lock that holds the two halves of a connector together or holds a connector to an electrical device. Usually an optional device. It prevents accidental release of the connector lock and serves as an indicator of full connector mating. CT Continuity Tester. A made-up test device composed of a data analyzer and a continuity monitor. CUT Component Under Test DMM Digital Multimeter DVP&R Design Verification Plan and Report EWCAP Electrical Wiring Component Applications Partnership. One of several sub- groups of USCAR. Has the task of commonizing electrical components and interfaces. FMEA Failure Mode and Effects Analysis FMVSS Federal Motor Vehicle Safety Standard FS Full Scale GD&T Geometric Dimensioning and Tolerancing. A method required by the USCAR Companies for representing dimensions and their tolerances on all part drawings. IACS International Annealed Copper Standard IDC Insulation Displacement Connection. A means of attaching a terminal to a conductor where projections on the terminal pierce the conductor insulation to make electrical contact, rather than requiring the insulation to be removed. MVD Millivolt Drop. MVSS Motor Vehicle Safety Standard. SAE/USCAR-2 Revision 4 Revised May 2004 PERFORMANCE SPECIFICATION FOR AUTOMOTIVE ELECTRICAL CONNECTOR SYSTEMS - 85 - PLR Positive Latch Reinforcement. Also known as a Wedge, Spacer or Terminal Position Assurance (TPA) feature. It is installed or seated after the terminals are inserted into their housing to assure that the terminals are properly positioned. It either reinforces the primary terminal locking mechanism or provides a separate redundant terminal lock. PPAP Production Part Approval Process. RH Relative Humidity. TPA Terminal Position Assurance. See PLR. TUT Terminal Under Test. USCAR United States Council for Automotive Research. A consortium of representatives from Ford, General Motors and DaimlerChrysler to promote joint research in non- competitive areas that can strengthen the US automotive industry. SAE/USCAR-2 Revision 4 Revised May 2004 PERFORMANCE SPECIFICATION FOR AUTOMOTIVE ELECTRICAL CONNECTOR SYSTEMS - 86 - APPENDIX C: TESTS RECOMMENDED FOR NEW TOOLING, TOOL TRANSFER, OR MATERIAL CHANGE Ford, GM and DaimlerChrysler have jointly published a booklet entitled Production Part Approval Process (PPAP), which is available through the AIAG whose address can be found in Appendix B of this Specification. Section II of the PPAP booklet, When Submission Is Required, outlines the agreed upon conditions necessitating initial or resubmission of production parts for engineering approval. Among the Requirements For Part Approval, given in Section III of the booklet, is listed Material, performance and durability test results as specified on the design record. This table shows the recommended performance and durability tests for several of the Section II situations. The Authorized Person is the final authority as to which, if any, tests are required in any given situation. Requirements are generally listed in a Control Plan or similar document. Recommendations in this table are intended only as suggestions based on the past experiences of the USCAR/EWCAP team. SAE/USCAR-2 Revision 4 Revised May 2004 PERFORMANCE SPECIFICATION FOR AUTOMOTIVE ELECTRICAL CONNECTOR SYSTEMS - 87 - Test Seq. USCAR/EWCAP SAE/USCAR-2 Test Name Tool Transfer New/Capacity Tooling Material Change (1) Connector Terminal Connector Seal Terminal Connector Seal Terminal(2) Sealed Un-sealed Seal(3)(4) A Terminal to Terminal Engage/Disengage Force X X X B Terminal Bend Resistance X X C Maximum/Current Cycling X D Terminal-Connector Insertion/Extraction X X X X X X(5) E Miscellaneous Component Engage/ Disengage Force X X X X F Audible Click X X G Connector- Connector Mating/Unmating X X X X X H Polarization Effectiveness X X I Drop X X J Cavity Damage X X K Header Pin Retention X X L Mounting Feature Mech. Strength X X M Vibration/ Mechanical Shock (2) X X N Thermal Shock (2) X X O Temperature / Humidity Cycling (2) X X P High Temperature Exposure (2) X X Q Fluid Resistance X R Temp./Humidity - Submersion X X S Temp./Humidity PV Leak X X T High Temp Exposure - Submersion X X U High Temp. Exposure P/V Leak X X V Temp./Humidity X X W P/V Leak (Stand-alone) X X X X X(4) X indicates recommended tests to be performed on at least the minimum sample size of production parts for each test from the affected tooling. (1) “Material Change” includes the following: Terminal: Base material, hardness, plating, process and/or electrical lubricant. Connector: Base material/composition Seal: Base material, properties or process (2) All terminal material changes: perform 5.8.6 or USCAR-20 (3) Seal durometer change: perform 5.4.1-A (Terminal-Connector Insertion) and Test Sequence W (Pressure Vacuum Leak) only (4) Seal color change: perform Test Sequence W, Pressure/Vacuum Leak only. (5) Insertion only Table 8: Recommended Performance and Durablilty Tests SAE/USCAR-2 Revision 4 Revised May 2004 PERFORMANCE SPECIFICATION FOR AUTOMOTIVE ELECTRICAL CONNECTOR SYSTEMS - 88 - APPENDIX D: TESTS FOR NEW/EXISTING TERMINAL OR CONNECTOR DESIGNS Test seq SAE/USCAR-2 Test Name New Design Existing Connector with more or less cavities Terminal Sealed Connector Unsealed Connector Sealed Unsealed Existing Connector , New Polarization New Cable Seal/Application A Term. - Term. Engage/Disengage Force X B Terminal Bend Resistance X C Maximum Current/Current Cycling X D Term.-Conn. Insertion/Extraction X X E Misc. Component Engage/Disengage X X F Audible Click X X X X G Conn. Conn Mating/Un-mating X X X X H Polarization Effectiveness X X X X X I Drop X X J Cavity Damage X X K Header Pin Retention X X L Mounting Feature Mech Strength X X M Vibration X X X N Thermal Shock X X X O Temp./Humidity X X X P High Temp Exposure X X X Q Fluid Resistance X R Temp/Humidity-Submersion X S Temp/Humidity-PV Leak X T High Temp Exposure- Submersion X U High Temp Exposure- PV Leak X X V Temp/Humidity(2) X X W Pressure/Vacuum Stand Alone X (1) X (1) For terminals intended for sealed applications only (2) Must be performed for sealed and un-sealed systems if section 5.9.6 is omitted. SAE/USCAR-2 Revision 4 Revised May 2004 PERFORMANCE SPECIFICATION FOR AUTOMOTIVE ELECTRICAL CONNECTOR SYSTEMS - 89 - APPENDIX E: SOURCE LIST Reference material Supplier Engine Oil ASTM D471, IRM 902 Oil ISO 1817, Oil No. 2 & Power Steering ASTM D471, IRM 903 Oil ISO 1817, Oil No. 3 R. E. Carroll, Inc. P. O. Box 5806 Trenton, NJ 08638-0806 Phone: +1 800-257-9365 Fax: +1 609-695-0102 URL: Penreco 4426 East Washington Blvd. Los Angeles, CA 90023 Phone: +1 888-227-5448 Fax: +1 323-268-7972 URL: Swedish National Testing and Research Institute Box 857 SE-501 15 Bors Sweden Phone: +46 33 16 50 00 Fax: +46 33 10 33 88 http:/www.sp.se/eng/default.htm Automatic Trans Fluid SAE J311, Dexron III Citgo Part No. 33123 Citgo Petroleum 699 Heights Rd. Lake Orion, MI 48362 Phone: +1 800-331-4068 URL: Brake Fluid SAERM-66XX SAE Automotive Headquarters 400 Commonwealth Dr. Warrendale, PA. 15096-0001 or /servlets/otherProduct?Prod_CD=RM- 6605&PROD_TYP=RM Table 10: Materials and Sources SAE/USCAR-2 Revision 4 Revised May 2004 PERFORMANCE SPECIFICATION FOR AUTOMOTIVE ELECTRICAL CONNECTOR SYSTEMS - 90 - APPENDIX F: DESIGN NOTES Regarding maximum current rating: NOTE: The “Maximum Test Current Capability” (ref. section 5.3.3) test detailed in this document is only conducted to establish test parameters. The value obtained in this procedure is used to limit the current in the “1008 hr. current cycling test”. Data collected during this test can also be used to compare various terminals tested to the same specification. This test cannot establish the Maximum Current Capability of a specific terminal application. For specific applications, several factors other than current load must be considered. All of the following have an effect on the maximum current load that can be passed through a terminal grip and interface over the life of the vehicle. Wire size: Larger wire sizes can sink heat away from a terminal, into the harness and reduce the terminal operating temperature. The opposite is true for smaller wire sizes. Devices: Some devices can create heat while some can sink heat away from an interface. This can have a dramatic effect on the maximum current capability of a terminal system. Terminal location within a connector: Terminals carrying current loads located next to other terminals carrying current loads can cause hot spots or heat build up in a localized area within a connector and lead to terminal failure. At a given current load, terminals located in the corner connector cavities will run cooler than terminals in the center of the field. Sealed connectors: Sealed connectors can trap heat and cause terminals to run hotter than the same terminal at the same load in an unsealed connector. Ambient temperature: Terminals running in elevated temperature environments, such as engine compartments will have lower Maximum Current Capability than the same terminal/wire combination running in lower temperature locations. Terminals operating at cooler temperatures tend to exhibit less stress relaxation in the contact beams and less degradation to the coating and plating on their contact surfaces when compared to the same terminals operating at elevated temperatures. These factors have an effect on the maximum current load over the usable life span of a terminal system. SAE/USCAR-2 Revision 4 Revised May 2004 PERFORMANCE SPECIFICATION FOR AUTOMOTIVE ELECTRICAL CONNECTOR SYSTEMS - 91 - APPENDIX G: REVISIONS This specification was approved by USCAR/EWCAP in December 1999. Any revisions since that date have been incorporated into the specification. Revisions that altered the content of the specification are recorded below: DATE SECTION SUMMARY OF CHANGES MADE * NOTES 12/6/99 all Signed off by EWCAP team “Draft” removed 12/14/00 all Changes made and signed off by EWCAP team 1-10-01 p.2-21 Some figure references were corrected, but no technical content was affected. Current draft will now differ from